Install Brake Lines & Cylinders

After installing the rudder pedals, I installed the brake master cylinders and lines. I had hoped to fill the system, but found I need to use a special kind of aviation brake fluid which won't eat the seals. I have it on order and hope to complete next week.

Install Seats

I decided to install the seats so that I could climb in see how things felt. It was hard to determine if the rudder pedals were friction-free enough by using just my hands. After climbing in, my feet confirmed that they feel pretty good.

My Harbor Freight pneumatic riveter crapped out, so had to use a hand puller on stainless steel 3/16" rivets. Only way I could do it was use channel locks to squeeze the gun to generate enough leverage.
Zip ties were used to tension the underside of the seat fabric.

It took a solid day to get this done.

Floorboards & Rudder Pedals: Final Install

Since I'm awaiting Sunbrella fabric material to line the interior of the boot cowl, I decided to final install the rudder pedals and floor boards. The rudder and brake controls are actuated redundantly through push-pull tubes between fore and aft pedals.

Reagan (18 mo) gives the forward control stick a tug.

Boot Cowl Fit-up

Beginning the fitup of the fiber glass boot cowl. I used a dremel with cutting bits to cut areas around the edge where needed to clear fasteners, gear legs, etc. Pre-etched lines from the manufacturer helped tremendously in getting close with the cuts. Take caution in removing cowl during test fits, as will rub paint off fuse. I wish I had duct taped wear areas initially.

Firewall Final Install

Production has suffered lately, as have been out of town alot. The firewall is complete. I spray glued Sunbrella awning fabric to the inside of the firewall and burned holes through with a hot knife. I then installed all of the parts shown. Next I will fitup the boot cowling.

Fuselage Final Install: Flap Handle Control

Here are a couple pics of the flap handle installation...

In the last pic, you can see clearance problem with the armature. Will solve by using extra washers to shim up assembly.

Fuselage Final Install: Aileron Cable Control System

Installed a portion of the aileron control system before the wings go on, consisting of four pulleys and short runs of cable and turnbuckles tied to the torque tube.